Cooling Water Innovation: Harnessing Wastewater for Sustainability

In this episode of Scaling UP! H2O podcast, host Trace Blackmore dives into a conversation with Juan Meneses, District Manager at Nalco Water, An Ecolab Company to explore a groundbreaking innovation in industrial water treatment. Discover how Juan and his team harnessed treated wastewater to transform cooling tower systems, achieving a remarkable $4 million reduction in operational costs while championing sustainability. This episode highlights the challenges, strategies, and ultimate success of using treated sewage effluent—a game-changer for industries navigating water scarcity and operational efficiency.

What You’ll Learn in This Episode

The Steps to Integrating Treated Wastewater into Cooling Tower Systems 

Discover how Juan Meneses and his team approached the integration of treated sewage effluent into a refinery’s cooling tower system. Learn about the initial assessments of water quality, the detailed planning process, and the role of collaboration between industry experts and stakeholders in ensuring a seamless transition. From analyzing water chemistry to implementing treatment solutions, this episode walks you through every critical step.

How to Overcome Challenges Like Biofouling, Corrosion, and Scaling 

Integrating wastewater into industrial systems is no easy task. Juan Meneses shares the real-world obstacles his team encountered, such as high organic content, ammonia levels, and variations in water quality. Hear about the innovative strategies they used to combat biofilm formation, prevent corrosion caused by harsh chemicals, and minimize scale buildup—all while maintaining system reliability and efficiency.  

The Pivotal Role of Automation in Water Quality Management 

Learn how advanced monitoring systems and real-time data collection were game changers in this project. Juan explains the importance of automated sensors in detecting water quality fluctuations, adjusting chemical dosages, and ensuring that all parameters remained within operational limits. This segment highlights how technology can simplify complex processes and prevent costly errors.  

Real-World Examples of Achieving Sustainability Goals and Operational Excellence 

This case study is a testament to the power of innovation in addressing both environmental and business challenges. Juan outlines how his team’s efforts not only reduced freshwater usage and wastewater discharge but also saved the refinery $4 million in operational costs. This section offers practical insights into balancing sustainability objectives with financial performance, showcasing what’s possible with a forward-thinking approach.

This episode demonstrates how innovative water reuse strategies can align cost savings, operational reliability, and environmental stewardship.

Stay engaged, keep learning, and continue scaling up your knowledge! 

Timestamps  05:07 - Upcoming Events for Water Treatment Professionals  09:23 - Interview with Juan Meneses, District Manager from NalCo Water 15:18 – About the case study: using treated wastewater in cooling towers  20:32 – Automation and Innovation in Water Treatment 33:05 – Lesson learned and reflections from the project 42:42 – Water You Know with James McDonald

Connect with Juan Meneses  Phone: 337.309.9619 Email: jmeneses@ecolab.com Website: Reinventing the Way Water is Managed | Nalco Water LinkedIn: Juan A. Meneses | LinkedIn

Click HERE to Download Episode's Discussion Guide

Guest Resources Mentioned  IWC (International Water Conference)    Freakonomics Radio Podcast  Today, Explained Podcast  CH 1979 Innovation Synergies Enable Reliable Wastewater Reuse in Cooling Towers At 4 million Lower TCO paper Good Profit: How Creating Value for Others Built One Of The World’s Most Successful Company by Charles Koch  Crucial Conversations Tools for Talking When Stakes Are High, Second Edition: Kerry Patterson, Joseph Grenny, Ron McMillan, Al Switzler  The 4 Disciplines of Execution: Achieving Your Wildly Important Goals by Sean Covey (Author), Chris McChesney (Author), Jim Huling (Author) 

Scaling UP! H2O Resources Mentioned  AWT (Association of Water Technologies)    Scaling UP! H2O Academy video courses Submit a Show Idea The Rising Tide Mastermind  The 12 Week Year: Get More Done in 12 Weeks than Others Do in 12 Months 164 The One With Chris McChesney

Water You Know with James McDonald Question: What do you call sections in a water system with low or no flow due to system design and/or operation?  

2025 Events for Water Professionals  Check out our Scaling UP! H2O Events Calendar where we’ve listed every event Water Treaters should be aware of by clicking HERE.